JP7234637B2 - Manufacturing method of three-dimensional model - Google Patents

Description

The present invention relates to a method for manufacturing a three-dimensional structure.

Conventionally, there are various types of manufacturing methods for three-dimensional structures. Among these methods, there is a method for manufacturing a three-dimensional structure, in which a three-dimensional structure is manufactured by forming a layer, irradiating a laser to melt the layer, and then solidifying the layer. For example, Patent Literature 1 discloses a method for manufacturing a three-dimensional structure, which comprises forming a powder layer, irradiating the powder layer with a light beam to melt the layer, and then solidifying the layer to manufacture a three-dimensional structure. ing.

JP 2015-17294 A

In the method for manufacturing a three-dimensional structure disclosed in Patent Literature 1, a step of removing powder around the three-dimensional structure by suction and a step of cutting the surface of the three-dimensional structure are performed. By performing these processes, it is possible to manufacture a high-quality three-dimensional model, but the increase in the number of steps increases the production load of the three-dimensional model.

A method for manufacturing a three-dimensional structure according to the present invention for solving the above problems is a method for manufacturing a three-dimensional structure by laminating layers, the method comprising a material containing powder and a binder and a boundary region including at least one of the edge of the modeling region of the three-dimensional structure and the outer portion of the modeling region adjacent to the edge in the layer is irradiated with a laser. and a removing step of removing a part of the material in the boundary region, and a melting and solidifying step of melting and then solidifying the material in the modeling region by irradiating a laser.

1 is a schematic configuration diagram showing the configuration of a three-dimensional structure manufacturing apparatus according to an embodiment capable of executing the three-dimensional structure manufacturing method of the present invention; FIG. A flow chart of a method for manufacturing a three-dimensional structure according to an embodiment of the present invention. FIG. 5 is a cross-sectional view of a layer when a removal step is performed in the method for manufacturing a three-dimensional structure according to one embodiment of the present invention; FIG. 5 is a cross-sectional view of a layer when the removal step is not performed in the method for manufacturing a three-dimensional structure according to one embodiment of the present invention; FIG. 5 is a cross-sectional view of a layer showing another example of laser irradiation positions in the removing step in the method for manufacturing a three-dimensional structure according to one embodiment of the present invention. FIG. 5 is a cross-sectional view of a layer showing still another example of the laser irradiation position in the removal step in the method for manufacturing a three-dimensional structure according to one embodiment of the present invention; FIG. 4 is a cross-sectional view of a layer for explaining the laser irradiation intensity in the removing step in the method for manufacturing a three-dimensional structure according to one embodiment of the present invention; FIG. 5 is a cross-sectional view of a layer for explaining the laser irradiation position in the removal step in the method for manufacturing a three-dimensional structure according to an embodiment of the present invention, showing a state in which the entire boundary region is irradiated with the laser in the removal step; Schematic diagram representing . FIG. 4 is a plan view of a layer for explaining the laser irradiation position in the removal step in the method for manufacturing a three-dimensional structure according to an embodiment of the present invention, showing a state in which the entire boundary region is irradiated with the laser in the removal step; Schematic diagram representing . FIG. 4 is a cross-sectional view of a layer for explaining the laser irradiation position in the removal step in the method for manufacturing a three-dimensional structure according to an embodiment of the present invention, in which a part of the boundary region is irradiated with the laser in the removal step; The schematic showing a state. FIG. 4 is a plan view of a layer for explaining the laser irradiation position in the removal step in the method for manufacturing a three-dimensional structure according to an embodiment of the present invention, in which a part of the boundary region is irradiated with the laser in the removal step; The schematic showing a state. FIG. 12 is a plan view of a layer for explaining the laser irradiation position in the removal step in the method for manufacturing a three-dimensional structure according to an embodiment of the present invention, showing a boundary region at a position different from that in FIG. 11 in the removal step; The schematic showing the state which irradiated the laser to one part.

First, the present invention will be generally described.
A method for manufacturing a three-dimensional structure according to a first aspect of the present invention for solving the above-mentioned problems is a method for manufacturing a three-dimensional structure by laminating layers, comprising powder and A boundary including at least one of a layer forming step of forming a layer using a material containing a binder, and an end of a modeling region of the three-dimensional structure in the layer and an outer portion of the modeling region adjacent to the end A removal step of irradiating a region with a laser to remove a part of the material in the boundary region; characterized by

When a layer is irradiated with a laser to melt the material, the material is melted by drawing in the material around the irradiated position of the laser. For this reason, when moving the laser irradiation position in a line, at the first line position and the laser irradiation start position, there is material all around, so much material is drawn in and melted, and the protruding part of the layer tends to generate When the protruding portion is generated, the manufacturing accuracy of the three-dimensional structure is lowered. On the other hand, according to this aspect, since part of the material in the boundary region is removed in the removing step, it is possible to suppress the generation of the projecting portion. Therefore, it is possible to manufacture a high-quality three-dimensional structure. Note that since both the removing step and the melting and solidifying step are performed by irradiating the layer with a laser, these steps can be considered as one laser irradiation step, so that an increase in the number of steps can be suppressed. That is, according to this aspect, it is possible to manufacture a high-quality three-dimensional structure without increasing the number of steps.

In the method for manufacturing a three-dimensional structure according to the second aspect of the present invention, in the first aspect, the laser irradiation position in the removing step is the boundary region at the laser irradiation start position in the melting and solidifying step. characterized by comprising

According to this aspect, the laser irradiation position in the removing step includes the boundary region at the laser irradiation start position in the melting and solidifying step. That is, since a portion of the material at the laser irradiation start position in the melting and solidification process, which tends to generate a projecting portion, is removed, it is possible to effectively suppress the generation of a projecting portion in the layer.

A third aspect of the present invention is a method for manufacturing a three-dimensional structure according to the first or second aspect, wherein the laser irradiation in the melting and solidifying step is performed by moving the laser irradiation position linearly. The laser irradiation position in the removing step includes the boundary region in the width direction of the line.

According to this aspect, the laser irradiation position in the removing step includes the boundary region in the width direction of the line. When the laser irradiation position is moved linearly in the melting and solidifying step, a protruding portion is likely to be generated in the first line, especially along with the laser irradiation in the first line. Since part of the material in the boundary region on the line side can be removed, it is possible to effectively suppress the generation of a projecting portion in the layer.

A fourth aspect of the present invention is a method for manufacturing a three-dimensional structure according to any one of the first to third aspects, wherein the laser irradiation position in the removing step is the entire periphery of the modeling region. It is characterized by including a boundary region.

According to this aspect, the laser irradiation position in the removing step includes the boundary area around the entire periphery of the modeling area. That is, since part of the material is removed in all regions where protrusions are likely to be generated, it is possible to effectively suppress the formation of protrusions in the layer.

The method for manufacturing a three-dimensional structure according to a fifth aspect of the present invention is the method according to any one of the first to fourth aspects, wherein the laser intensity in the removing step is set to a temperature higher than the thermal decomposition temperature of the binder. The intensity is such that the irradiation position is heated to a temperature.

According to this aspect, the laser intensity in the removing step is an intensity at which the laser irradiation position is heated to a temperature equal to or higher than the thermal decomposition temperature of the binder. For this reason, the binder at the laser irradiation position can be thermally decomposed to effectively remove part of the material at that position.

A sixth aspect of the present invention is a method for manufacturing a three-dimensional structure according to any one of the first to fifth aspects, wherein the laser intensity in the removing step exceeds one layer of the layer. is less than the intensity reached by the irradiation energy of

According to this aspect, the laser intensity in the removal step is less than the intensity that the laser irradiation energy reaches beyond one layer. By setting the laser intensity in such a manner, it is possible to suppress the occurrence of defective removal of the material in the removing step due to the residual melted residue of the layer remaining at the laser irradiation position.

Hereinafter, embodiments according to the present invention will be described with reference to the accompanying drawings.
First, an overview of a three-dimensional structure manufacturing apparatus 1 capable of executing the three-dimensional structure manufacturing method of the present invention will be described with reference to FIG.
Here, the X direction in the drawing is the horizontal direction, and the Y direction is the horizontal direction and perpendicular to the X direction. The Z direction is the vertical direction and corresponds to the stacking direction of the layers 12 shown in FIG. 3 and the like.

A three-dimensional structure manufacturing apparatus 1 of the present embodiment is a three-dimensional structure manufacturing apparatus that manufactures a three-dimensional structure O by stacking layers 12 . As shown in FIG. 1, the apparatus 1 for manufacturing a three-dimensional structure according to the present embodiment includes an injection unit 7, a modeling table 11, a drying unit 8, a laser irradiation unit 20, which will be described later, and driving and moving them. and a control unit 3 for controlling the In addition, as shown in FIG. 1, the apparatus 1 for manufacturing a three-dimensional structure according to the present embodiment includes a housing portion 16 that creates a sealed space inside, and nitrogen gas is supplied from a cylinder 13 to the inside of the housing portion 16. A gas pipe 14 that can be introduced and a gas pipe 15 for exhausting the gas inside the housing part 16 are provided.

In addition, the injection unit 7 of the present embodiment is configured to be capable of injecting a fluid material (fluid material) containing a powder, a solvent, and a binder, which constitutes the three-dimensional structure O, in the form of droplets. . Furthermore, the injection unit 7 of the present embodiment can inject, in addition to the fluid material, a fluid support material that supports the fluid material at the end of the layer 12 in the form of droplets, if necessary. It is configured.

In addition, as shown in FIG. 1 , the injection section 7 of the present embodiment is installed in the injection section unit 4 . In addition, the injection unit 7 of the present embodiment is configured to be able to eject the fluid material and the support material while moving in the Y direction, and is configured to be movable along the Z direction. It has an adjustable configuration for the gap of

Further, the modeling table 11 of this embodiment is movable along the X direction, and the layer 12 is formed on the modeling surface 11a by the fluid material injected from the injection unit 7 . Here, the modeling table 11 can be moved from the injection unit 4 to the drying unit 5 and further to the laser unit 6 by moving in the X1 direction of the X directions. Furthermore, the modeling table 11 can also move in the direction opposite to the X1 direction of the X directions, forming the layer 12 in the jet unit 4, drying the layer 12 in the drying unit 5, After finishing the irradiation of the layer 12 with the laser L in the unit 6, it is possible to return to the jet unit 4 again to form the next layer 12. FIG.

Further, the drying section 8 of the present embodiment is configured to be capable of drying the layer 12 by volatilizing the solvent contained in the layer 12 formed on the modeling table 11 . The drying unit 8 of the present embodiment is a line heater extending along the Y direction, and can irradiate the layer 12 formed on the modeling table 11 with infrared rays to dry the layer 12. It is configured. However, the drying section 8 is not limited to such a configuration, and may be other than a line heater, and may be configured other than a configuration that irradiates electromagnetic waves such as infrared rays. Moreover, as shown in FIG. 1, the drying section 8 of this embodiment is installed in the drying unit 5 .

In addition, the laser irradiation section 20 of this embodiment is composed of the laser generation section 10 and the galvanomirror 9 . Here, the galvanomirror 9 is configured to be able to change the arrangement of mirrors (not shown) provided therein within a predetermined angle range and to be movable along the Z direction. With such a configuration, it is possible to continue to focus the laser L even when the layers 12 are stacked, and it is configured to be able to irradiate the laser L to the entire range of the modeling surface 11a. there is Moreover, as shown in FIG. 1, the laser irradiation section 20 of the present embodiment is installed in the laser unit 6 .

Here, as shown in FIG. 1, the apparatus 1 for manufacturing a three-dimensional structure according to the present embodiment, when forming the layer 12 on the modeling surface 11a by injecting the fluid material from the injection unit 7, the drying unit When the layer 12 is dried by irradiating the layer 12 with infrared rays from 8 and when the laser L is irradiated from the laser irradiation unit 20, the modeling table 11 is arranged so that the modeling surface 11a is horizontal.

Next, a fluid material that can be used in the three-dimensional structure manufacturing apparatus 1 of this embodiment will be described in detail.
Examples of the constituent material (powder) of the three-dimensional structure O include magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), Single powder of nickel (Ni), or alloys containing one or more of these metals (maraging steel, stainless steel (SUS), cobalt chromium molybdenum, titanium alloys, nickel alloys, aluminum alloys, cobalt alloys, cobalt chromium alloys), etc. The mixed powder can be used as a pasty mixed material containing a binder.
General-purpose engineering plastics such as polyamide, polyacetal, polycarbonate, modified polyphenylene ether, polybutylene terephthalate, and polyethylene terephthalate can also be used. In addition, engineering plastics (resins) such as polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide, and polyetheretherketone can also be used.
As described above, there is no particular limitation on the constituent materials of the three-dimensional structure O, and metals other than the above metals, ceramics, resins, and the like can also be used. Also, silicon dioxide, titanium dioxide, aluminum oxide, zirconium oxide, etc. can be preferably used.
Furthermore, fibers such as cellulose can also be used.

Examples of binders include acrylic resins, epoxy resins, silicone resins, cellulose resins, other synthetic resins, PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide), and other thermoplastic resins. Alternatively, they can be used in combination.

In addition, the fluid material may further contain a solvent. Preferred solvents include, for example, water; ) alkylene glycol monoalkyl ethers; acetic acid esters such as ethyl acetate, n-propyl acetate, iso-propyl acetate, n-butyl acetate and iso-butyl acetate; aromatic hydrocarbons such as benzene, toluene and xylene; methyl ethyl ketone , acetone, methyl isobutyl ketone, ethyl-n-butyl ketone, diisopropyl ketone, ketones such as acetylacetone; alcohols such as ethanol, propanol, butanol; tetraalkylammonium acetates; dimethyl sulfoxide, sulfoxide solvents such as diethyl sulfoxide; pyridine , γ-picoline, pyridine-based solvents such as 2,6-lutidine; ionic liquids such as tetraalkylammonium acetate (e.g., tetrabutylammonium acetate, etc.); They can be used in combination.

In addition, the physical properties of the fluid material that can be used in the three-dimensional structure manufacturing apparatus 1 of the present embodiment are not particularly limited. It is not limited to a liquid but may be a gel as long as it deforms under the influence of gravity when placed. However, those having a viscosity of 500 mPa·s or more and 100000 mPa·s or less in the low shear rate range are particularly preferably used.

Next, an embodiment of a three-dimensional structure manufacturing method using the three-dimensional structure manufacturing apparatus 1 will be described with reference to the flow chart of FIG. 2 and FIGS. 3 to 12. FIG. Here, in the method for manufacturing a three-dimensional structure according to the present embodiment, for example, in the removal step of step S140 described later, as shown in FIGS. 12, or intermittently moving the laser L linearly in the direction of the arrow N0 as shown in FIG. do. In addition, in the manufacturing method of the three-dimensional structure of the present embodiment, for example, as shown in FIGS. The material of the three-dimensional structure O at the irradiation position is melted by irradiating while moving linearly in the direction of the arrow N1, the direction of the arrow N2, and so on. Hereinafter, the trajectory of the irradiation of the laser L that is moved in a line is simply referred to as a line.

In the method for manufacturing a three-dimensional structure according to the present embodiment, first, as shown in the flowchart of FIG. 2, in a structure data input step of step S110, modeling data for a three-dimensional structure to be manufactured is input. The input source of the modeling data of the three-dimensional structure is not particularly limited, but the modeling data can be input to the three-dimensional structure manufacturing apparatus 1 using a PC or the like.

Next, in the layer forming process of step S120, the layer 12 is formed on the modeling table 11 by injecting the fluid material from the injection unit 7 shown in FIG. The state after executing this step is as shown in the state diagram at the top of FIG.

Next, in the solvent drying step of step S130, the drying section 8 dries the solvent contained in the fluid material forming the layer 12. FIG. However, in the manufacturing method of the three-dimensional structure of the present embodiment, it is possible to omit this step.

Next, in the removal step of step S140, the boundary region 25 including at least one of the edge 17 of the modeling region 23 of the three-dimensional structure O in the layer 12 and the outer portion 22 of the modeling region 23 adjacent to the edge 17 is removed. A part of the fluid material in the boundary region 25 is removed by irradiating a laser L on at least a part of to scatter a part of the fluid material. By executing this step, for example, the second state diagram from the top in FIG. 3 changes to the third state diagram from the top in FIG. In FIG. 3, as can be seen by referring to the fourth state diagram from the top in FIG. After part of the fluid material is removed, the laser L is irradiated again to melt and solidify the fluid material. However, a portion of the flowable material may be removed at the outer portion 22 of the build area 23, as represented in FIG. A portion of the flowable material may be splashed at locations on both outer portions 22 of 23 .

Here, it is preferable that the laser intensity in the removal step of step S140 is an intensity at which the irradiation position of the laser L is heated to a temperature higher than the thermal decomposition temperature of the binder contained in the fluid material. This is because by setting the strength to such a value, the binder at the irradiation position of the laser L can be thermally decomposed to scatter the fluid material, and a part of the fluid material at the position can be effectively removed.

Moreover, the laser intensity in the removal step of step S140 is preferably less than the intensity at which the irradiation energy of the laser L reaches beyond one layer of the layer 12 . This is because by setting the laser intensity to such a value, it is possible to prevent the melted residue 24 of the layer 12 from remaining at the irradiation position of the laser L, thereby preventing the removal failure of the fluid material from occurring in the removal step.

Here, FIG. 7 shows the formation state of the recess 21 when the laser L is irradiated with a preferable laser intensity, which is less than the intensity at which the irradiation energy of the laser L reaches beyond the layer 12 for one layer. 21a is shown. In addition, FIG. 7 shows a concave portion 21b which is a formation state of the concave portion 21 when the laser L is irradiated with an unfavorable laser intensity, which is an intensity at which the irradiation energy of the laser L reaches beyond the layer 12 for one layer. and a recess 21c are shown. As shown by the recesses 21 b and 21 c , if the laser intensity is such that the irradiation energy of the laser L reaches beyond one layer of the layer 12 , the melt residue 24 may remain in the recesses 21 . If the molten residue 24 remains in the concave portion 21, unevenness may be formed in the layer 12 after the melting and solidifying process, which is not preferable.

In addition, in the removing step of step S140, for example, as shown in FIGS. can be removed in part. 10, 11, and 12, a part of the boundary region 25 of the modeling region 23 of the three-dimensional modeled object O in the layer 12 is irradiated with the laser L to remove the fluid material. A part can also be removed.

Here, FIG. 10 and FIG. 11 show the case where the laser L is moved in the same direction for all lines, ie, the first line, the second line, . . . 11 corresponds to the case where the irradiation start position of the laser L is the same for all lines on the upper side in FIG. On the other hand, FIG. 12 shows the case where the laser L is alternately moved in the opposite direction for the first line, the second line, and so on in the melting and solidifying process of step S150, that is, the irradiation start position of the laser L in the melting and solidifying process is set for each line. 12 alternately opposite to the upper and lower sides in FIG. To summarize, in FIGS. 8 and 9, in the removal step of step S140, all the boundaries of the position along the first line, the position along the last line, and the positions corresponding to the start and end positions of each line. A region 25 is irradiated with a laser L. 10, 11, and 12, in the removal step of step S140, the boundary region 25 at the position along the first line and the position corresponding to the start position of each line is irradiated with the laser L. ing.

Next, in the melting and solidification step of step S150, the layer 12 is irradiated with the laser L from the laser irradiation unit 20 to melt the constituent material of the three-dimensional structure O in the modeling region 23 of the layer 12. After melting, the material is cooled or left to stand. The constituent material of the three-dimensional structure O is solidified by, for example, solidifying. By executing this step, for example, the fourth state diagram from the top in FIG. 3 changes to the fifth state diagram from the top in FIG. . Then, for example, as shown in the sixth state diagram from the top of FIG. 3 to the bottom state diagram of FIG. . . , and the melted and solidified portion 19 is formed in the layer 12 for all areas of the modeling area 23 . Note that since the layer 12 is irradiated with the laser L from the same laser irradiation unit 20 in the removal process of step S140 and the melting and solidification process of step S150, these can be collectively considered as one laser irradiation process.

Then, in the determination step of step S160, the controller 3 determines whether or not the layer formation based on the modeling data input in step S110 has been completed. If it is determined that the layer formation has not been completed, the process returns to step S120 to form the next layer 12 . On the other hand, when it is determined that all layer formation is completed, the method of manufacturing a three-dimensional structure according to the present embodiment is terminated.

Here, the reason for performing the removal process of step S140 is demonstrated using FIG.3 and FIG.4. First, referring to FIG. 4, the case of manufacturing the three-dimensional structure O without performing the removal step of step S140 will be described. From the state in which the layer 12 is formed on the build table 11 represented by the top state diagram of FIG. When the end portion 17 of the modeling area 23 of the original object O is irradiated with the laser L of the first line, as shown in the third state diagram from the top in FIG. Since the heat reaches both sides, a portion of the fluid material on both sides is also drawn in to form the melted and solidified portion 19 of the first line. On the other hand, from the second line onward, as shown in the fourth state diagram from the top in FIG. One line of the melted solidified portion 19 is formed by drawing a portion of the fluid material only on one side of the irradiation position of the laser L in the Y direction. For this reason, the first line and the second and subsequent lines differ in the amount of the constituent material of the three-dimensional structure O used to form the melted and solidified portion 19 for one line. Only the amount of the constituent material of the three-dimensional structure O used to form the portion 19 is increased. Therefore, as shown in the state diagram at the bottom of FIG. 4, a convex portion 18 is formed at the position corresponding to the melted and solidified portion 19 on the first line, that is, at the end portion 17 of the modeling area 23. .

On the other hand, as shown in FIG. 3, if the removal step of step S140 is performed, a part of the fluid material in the boundary region 25 is removed when forming the melted solidified portion 19 of the first line. The amount of the constituent material of the three-dimensional structure O used to form the melted and solidified portion 19 for one line can be made uniform between the first line and the second and subsequent lines. Therefore, as shown in the state diagram at the bottom of FIG. 3, it is possible to suppress the formation of a convex portion at a position corresponding to the melted and solidified portion 19 of the first line.

In the above description, it has been explained that when the three-dimensional structure O is manufactured without performing the removing step, the convex portion 18 is likely to be formed at the position corresponding to the melted and solidified portion 19 on the first line. In other words, it has been explained that the protruding portion is likely to be formed along the line direction of the first line in the boundary area 25 . However, the irradiation start position of the laser L in the melting and solidifying process in the boundary region 25, that is, the starting position of the arrow direction N1, the arrow direction N2, . . . in FIGS. In addition, protrusions are likely to be formed at corresponding positions on the second and subsequent lines. Then, although it is not as large as the projecting portion along the line direction of the first line or the projecting portion formed at the irradiation start position of the laser L in the melting and solidifying process, it is formed in the other boundary area 25 of the modeling area 23 of the three-dimensional structure O. may also form protrusions. In the method for manufacturing a three-dimensional structure according to the present embodiment, it is possible to remove part of the fluid material from any portion of the boundary region 25 in the removal step.

Here, once summarized, as described above, the method of manufacturing a three-dimensional structure according to the present embodiment is a method of manufacturing a three-dimensional structure in which the three-dimensional structure O is manufactured by laminating the layers 12 . Then, corresponding to step S120, there is a layer forming step of forming the layer 12 using a fluid material containing powder and a binder. In addition, corresponding to step S140, the laser beam is applied to the boundary region 25 including at least one of the edge 17 of the modeling region 23 of the three-dimensional structure O in the layer 12 and the outer portion 22 of the modeling region 23 adjacent to the edge 17. It has a removing step of removing part of the fluid material in the boundary region 25 by irradiating L to scatter part of the fluid material. Also, corresponding to step S150, there is a melting and solidifying step of irradiating the laser L to melt the fluid material in the modeling area 23 and solidifying after melting.

As described above, when the layer 12 is irradiated with the laser L to melt the fluid material, the fluid material around the irradiation position of the laser L is drawn in and melted. For this reason, as shown in the state diagram at the bottom of FIG. , the flowable material all around tends to draw in and melt more of the flowable material, creating protrusions such as bumps 18 in layer 12 . The production accuracy of the three-dimensional structure O decreases when the projecting portion is generated. On the other hand, the method of manufacturing a three-dimensional structure according to the present embodiment removes part of the fluid material in the boundary region 25 in the removal step, so it is possible to suppress the formation of protrusions. Therefore, a high-quality three-dimensional structure O can be manufactured by executing the method for manufacturing a three-dimensional structure according to the present embodiment. Since both the removing process and the melting and solidifying process are performed by irradiating the layer 12 with the laser L, these processes can be considered as one irradiation process of the laser L, thereby suppressing an increase in the number of processes. That is, by executing the method for manufacturing a three-dimensional structure according to this embodiment, a high-quality three-dimensional structure O can be manufactured without increasing the number of processes.

Further, as described above, in the method for manufacturing a three-dimensional structure according to the present embodiment, as shown in FIGS. The formation position can include the boundary region 25 at the start position of each of the arrow directions N1, N2, . In this way, by making the irradiation position of the laser L in the removal process include the boundary region 25 at the irradiation start position of the laser L in the melting and solidifying process, the laser in the melting and solidifying process that easily generates a projecting portion A part of the fluid material at the irradiation start position of L can be removed, and generation of a projecting portion in the layer 12 can be effectively suppressed.

Further, as described above, in the method for manufacturing a three-dimensional structure according to the present embodiment, as shown in FIGS. The irradiation position of L is moved, and the irradiation position of the laser L in the removing process can include the boundary region 25a in the width direction of the line in the boundary region 25 . When the irradiation position of the laser L is moved linearly in the melting and solidifying step, it is particularly easy to generate a projecting portion at the position of the first line, which is the first line, due to the laser irradiation on the first line. Since part of the fluid material in the boundary region 25a in the width direction, ie, for example, the boundary region 25a on the side of the first line, can be removed, it is possible to effectively prevent the layer 12 from forming a projecting portion.

Further, as described above, in the method for manufacturing a three-dimensional structure according to the present embodiment, as shown in FIG. can include That is, by executing the method for manufacturing a three-dimensional structure according to the present embodiment, part of the fluid material is removed in all regions where protruding portions are likely to be generated, so that protruding portions are not generated in the layer 12. can be effectively suppressed.

The present invention is not limited to the above-described embodiments, and can be implemented in various configurations without departing from the spirit of the present invention. For example, the technical features in the examples corresponding to the technical features in the respective modes described in the Summary of the Invention are used to solve some or all of the above problems, or Substitutions and combinations may be made as appropriate to achieve part or all. Also, if the technical features are not described as essential in this specification, they can be deleted as appropriate.

DESCRIPTION OF SYMBOLS 1... Three-dimensional structure manufacturing apparatus, 2...PC, 3...Control part, 4...Injection part unit,
5...Drying unit, 6...Laser unit, 7...Injection part, 8...Drying part,
9 Galvanomirror 10 Laser generator 11 Modeling table 11a Modeling surface
12... Layer of three-dimensional structure O, 13... Cylinder, 14... Gas pipe, 15... Gas pipe,
16... Case part, 17... End part, 18... Convex part (protruding part), 19... Melt and solidify part,
20... laser irradiation part, 21... recessed part, 21a... recessed part, 21b... recessed part, 21c... recessed part,
22... Outer portion, 23... Modeling area, 24... Molten residue, 25... Boundary area,
25a... Boundary area, 25b... Boundary area, L... Laser, O... Three-dimensional structure

Claims (6)

A method for manufacturing a three-dimensional structure by laminating layers, comprising:
A layer forming step of forming a layer using a material containing powder and a binder;
A boundary region including at least one of an edge of the modeling region of the three-dimensional structure and an outer portion of the modeling region adjacent to the edge of the layer is irradiated with a laser, and part of the material in the boundary region a removing step of removing
a melting and solidifying step of irradiating the laser again to melt the material in the modeling region after the removing step is completed, and then solidifying the material after melting;
A method for manufacturing a three-dimensional structure, comprising: In the method for manufacturing a three-dimensional structure according to claim 1,
A method for manufacturing a three-dimensional structure, wherein the laser irradiation position in the removing step includes the boundary region at the laser irradiation start position in the melting and solidifying step. In the method for manufacturing a three-dimensional structure according to claim 1 or 2,
The laser irradiation in the melting and solidifying step is performed by moving the laser irradiation position in a line,
A method for manufacturing a three-dimensional structure, wherein the laser irradiation position in the removing step includes the boundary region in the width direction of the line. In the method for manufacturing a three-dimensional structure according to any one of claims 1 to 3,
A method for manufacturing a three-dimensional structure, wherein the laser irradiation position in the removing step includes the boundary region around the entire periphery of the modeling region. In the method for manufacturing a three-dimensional structure according to any one of claims 1 to 4,
The method for manufacturing a three-dimensional structure, wherein the laser intensity in the removing step is an intensity that reaches a temperature at which the laser irradiation position is heated to a temperature equal to or higher than the thermal decomposition temperature of the binder. In the method for manufacturing a three-dimensional structure according to any one of claims 1 to 5,
A method for manufacturing a three-dimensional structure, wherein the laser intensity in the removing step is less than the intensity at which the laser irradiation energy reaches beyond one layer of the layer.

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